Flexco Standard-Duty PTEZ, Heavy-Duty PTEZ Installation, Operation And Maintenance Manual
PTEZ™ Belt Trainer
Installation, Operation
and Maintenance Manual
Standard-Duty PTEZ
www.flexco.com
www.flexco.com
Heavy-Duty PTEZ
PTEZ
™
Belt Trainer
Serial Number: _____________________________________________________________
Purchase Date: ______________________________________________________________
Purchased From: ____________________________________________________________
Installation Date: ____________________________________________________________
Serial number information can be found on the Serial Number Label
on the product.
is information will be helpful for any future inquiries or questions
about belt cleaner replacement parts, specications or troubleshooting.
2 PTEZ™ Belt Trainer
Table of Contents
Section 1 - Important Information ...................................................................................................4
1.1 General Introduction ...........................................................................................................................4
1.2 User Benets .........................................................................................................................................4
1.3 Proper Belt Trainer Selection ..............................................................................................................5
Section 2 - Safety Considerations and Precautions ..........................................................................6
2.1 Stationary Conveyors ...........................................................................................................................6
2.2 Operating Conveyors ...........................................................................................................................6
Section 3 - Pre-Installation Checks and Options ..............................................................................7
3.1 Checklist ................................................................................................................................................7
3.2 Optional Installation Accessories .......................................................................................................8
Section 4 - Installation Instructions ..................................................................................................9
4.1 PTEZ ......................................................................................................................................................9
4.2 HD PTEZ.............................................................................................................................................12
Section 5 - Pre-Operation Checklist and Testing ............................................................................16
5.1 Pre-Op Checklist ................................................................................................................................16
5.2 Test Run the Conveyor ......................................................................................................................16
Section 6 - Maintenance...................................................................................................................17
6.1 New Installation Inspection ..............................................................................................................17
6.2 Routine Visual Inspection .................................................................................................................17
6.3 Routine Physical Inspection .............................................................................................................17
6.4 Roller Replacement Instructions ......................................................................................................18
6.5 Maintenance Log ................................................................................................................................19
6.6 Maintenance Checklist ......................................................................................................................20
Section 7 - Troubleshooting ............................................................................................................21
Section 8 - Specs and CAD Drawings ..............................................................................................22
8.1 CAD Drawing - PTEZ .......................................................................................................................22
8.2 CAD Drawing - HD PTEZ................................................................................................................23
8.3 CAD Drawing - HD PTEZ Underground ......................................................................................24
Section 9 - Replacement Parts .........................................................................................................25
9.1 Replacement Parts List - PTEZ ........................................................................................................25
9.2 Replacement Parts List - HD PTEZ .................................................................................................26
Section 10 - Other Flexco Conveyor Products ................................................................................ 27
3
Section 1 - Important Information
1.1 General Introduction
We at Flexco are very pleased that you have selected a PTEZ™ Belt Trainer for your conveyor system.
is manual will help you to understand the installation, operation and maintenance of this product and assist
you in making it work up to its maximum eciency over its lifetime of service.
It is essential for safe and ecient operation that the information and guidelines presented be properly
understood and implemented. is manual will provide safety precautions, installation instructions,
maintenance procedures and troubleshooting tips. In addition, please follow all standard, approved safety
guidelines when working on your conveyor.
If, however, you have any questions or problems that are not covered, please visit our web site or contact our
Customer Service Department:
Customer Service: 1-800-541-8028
Visit www.exco.com for other Flexco locations and products.
Please read this manual thoroughly and pass it on to any others who will be directly responsible for installation,
operation and maintenance of this belt trainer. While we have tried to make the installation and service tasks
as easy and simple as possible, this product does however require correct installation and regular inspection
and maintenance to maintain top working condition.
1.2 User Benets
Belt mistracking is a common problem that produces various problems, ranging from belt and structure damage
to product spillage and safety issues. By utilizing the PTEZ™, it is possible to correct a belt that is mistracking and
causing these problems. Multiple units may be required depending on the length of the mistracking belt.
4 PTEZ™ Belt Trainer
Section 1 - Important Information
1.3 Proper Belt Trainer Selection
MODEL APPLICATION RANGE
Belt Positioner
™
Return side only, 800 PIW max tension on Small,
Medium and Large; 1200 PIW max tension on Extra
Large. Also works on reversing belts.
PTEZ
™
Medium-duty belts up to 1600 PIW max tension.
Also works on reversing belts. Belt width 18"-48"
(450 - 1200mm).
PT Smart
™
Medium-duty belts up to 1600 PIW max tension.
Belt width 42" - 84" (050 - 2100mm). Belt thickness
1" (25mm) maximum.
HD PTEZ
™
Medium-duty belts up to 2400 PIW max tension.
Belt widths + 9" (225mm) idler. Belt thickness 1"
(25mm) maximum. Also works on reversing belts.
PT Pro
™
Medium-duty belts 150 PIW min to 1600 PIW max
tension. Belt width 18" - 72" (450 - 1800mm). Also
works on reversing belts.
HD PT Pro
™
Heavy-duty belts 300 PIW min to 2400 PIW max
tension. Belt width 48" - 96" (1200 - 2400mm). Also
works on reversing belts.
PT Max
™
Heavy-duty belts up to 3000 PIW max
Generally 3/4" to 1" thick (19mm to 25mm)
Belt width 24" - 60" (600 - 1500mm)
HD PT Max
™
Heavy-duty belts up to 6000 PIW max tension. Belt
width 54" - 84" (1350 - 2100mm)
Belt Positioner
™
PTEZ
PT Smart
™
Standard
HD PTEZ
PT Pro
PT Max
™
™
™
Top Side
™
™
PT Max
Return Side
Conveyor Criteria
Top side mistracking No No No No No No Ye s Yes Ye s
Return side mistracking Yes Yes Yes Ye s Yes Yes Yes Ye s Yes
Reversing Yes Yes Yes No Yes Yes No No No
Belt mistracking to one side Better Better Better Better Better Better Better Better Better
Belt mistracking to both sides Acceptable Better Better Best Better Better Best Best Best
Inconsistent tracking problem Good Better Better Best Better Better Best Best Best
Belt is cupped (heavy) Best ‡ Better ‡ Better ‡ Better Better Better Better Better Better
Belt has edge damage Best Best Best Good Best Best Good Good Good
Ease of Installation Best Better Better Good Good Good Good Good Good
Belt has low running tension (150-300 PIW) Good Good Good Good Good N/A Good N/A N/A
Belt has medium running tension (300-1600 PIW) Better Better Better Better Better Better Best Best Best
Belt has high running tension (1600+ PIW) N/A N/A N/A N/A N/A Best Better Best Best
Approx. "upstream" effect *∆ 50' (15 M) 20' (6 M) 20' (6 M) 20' (6 M) 20' (6 M) 20' (6 M) 50' (15 M) 50' (15 M) 50' (15 M)
Approx. "downstream" effect *∆ 50' (15 M)
‡ Installed on the clean side of the return belt
* Typical results; actual results may vary
∆ Disc idlers have the potential to reduce these numbers
Belt
Positioner
™
PTEZ
100' – 120'
(30 – 36 M)
™
Heavy
Duty
PTEZ
100' – 120'
(30 – 36 M)
PT Smart™PT Pro
™
120' – 150'
(36 – 45 M)
100' – 120'
(30 – 36 M)
™
Heavy
Duty
PT Pro
100' – 120'
(30 – 36 M)
™
PT Max
150' – 200'
(45 – 61 M)
™
Heavy
Duty
PT Max
150' – 200'
(45 – 61 M)
™
Super
Duty
PT Max
150' – 200'
(45 – 61 M)
™
5
Section 2 - Safety Considerations and Precautions
Before installing and operating the PTEZ™ Belt Trainer, it is important to review and understand the following safety
information.
ere are setup, maintenance and operational activities involving both stationary and operating conveyors. Each case
has a safety protocol.
2.1 Stationary Conveyors
e following activities are performed on stationary conveyors:
• Installation • Idler replacement
• Cleaning • Repairs
!
DANGER
It is imperative that OSHA/MSHA Lockout/Tagout
(LOTO) regulations, 29 CFR 1910.147, be followed
before undertaking the preceding activities. Failure to
use LOTO exposes workers to uncontrolled behavior of
the belt trainer caused by movement of the conveyor belt
or belt trainer. Severe injury or death can result.
Before working:
• Lockout/Tagout the conveyor power source
• Clear the conveyor area where work is to take place
!
WARNING
Use Personal Protective Equipment (PPE):
• Safety eyewear
• Hardhats
• Safety footwear
Close quarters and heavy components create a worksite
that compromises a worker’s eyes, feet and skull.
PPE must be worn to control the foreseeable hazards
associated with conveyor belt components. Serious
injuries can be avoided.
2.2 Operating Conveyors
ere are two routine tasks that must be performed while the conveyor is running:
• Inspection of belt trainer performance
• Dynamic troubleshooting
!
DANGER
!
WARNING
Every belt conveyor is an in-running nip hazard. Never
touch or prod an operating belt trainer. Conveyor
hazards cause instantaneous amputation and entrapment.
!
WARNING
Conveyors contain moving hazards. Stay as far from the
trainer as practical and use safety eyewear and headgear.
6 PTEZ™ Belt Trainer
Never adjust anything on an operating belt trainer.
Flailing hardware can cause serious injury or death.
Section 3 - Pre-installation Checks and Options
3.1 Checklist
• Check the model and size of the belt trainer. Is it the right one for your beltline?
• Check the PTEZ™ to be sure all the parts are included in the shipment.
– Trainer
–
Mounting hardware
– Instruction kit
• Find the information packet in the shipment
• Review the “Tools Needed” section on the front of the installation instructions.
• Prepare the conveyor site:
– Identify the point(s) of mistracking, expecting 100'- 120' (30-37 M) of downstream inuence.
– Position the unit 20' (6.1 M) aer the start of the mistracking.
– Identify an opening of at least 9" (225mm) for Standard Duty, 10.5" (265mm) for Heavy Duty if possible to
avoid interference with roller during installation.
– Remove old tracking devices.
– If the conveyor has disc idlers, replace one idler before and one idler aer the location where the trainer
will be installed with a standard idler.
– If the conveyor has V-return idlers, replace one idler before and aer where the trainer will be located with
a standard at idler.
7
Section 3 - Pre-Installation Checks and Options (cont.)
3.2 Optional Installation Accessories
Optional tools can make the installation of the PTEZ™ Belt Trainer easier and faster.
Flex-Lifter™ Conveyor Belt Lifter
Description
Medium Flex-Lifter 36" - 60" (900 - 1500mm) FL-M 76469
Large Flex-Lifter 48" - 72" (1200 - 1800mm) FL-L 76470
XL Flex-Lifter 72" - 96" (1800-2400mm) FL-XL 76983
Ordering
Number
Flex-Lier™ Conveyor Belt Lier
e Flexco Flex-Lier makes the job of liing the
conveyor belt easy and safe. Using two Flex-Liers,
the belt can be quickly lied out of the way to install
the PTEZ™. e Flex-Lier has the highest safe
li rating available at 4000 lbs (1810 kg). And it’s
versatile. It can also be used to li topside or return
side belt for splicing, roller replacement or other
maintenance jobs. Available in three sizes: Medium
for belt widths 36" - 60" (900 - 1500mm), Large for
belt widths 48" - 72" (1200 - 1800mm), and XL for
belt widths 72" - 96" (1800 - 2400mm).
Item
Code
8 PTEZ™ Belt Trainer
Section 4 - Installation Instructions - PTEZ
™
4.1 PTEZ
™
Roller
Mounting Bracket
Dust Cover
Main Shaft
Main Shaft
Bracket
Physically lock out and tag the conveyor at the power source
before you begin belt trainer installation.
Main Shaft
End Cap
CAUTION: Components may be heavy. Use safety-approved liing procedures.
Before You Begin:
• A serial number label is located in the instruction packet. Following
installation, please locate space on or near the PTEZ to apply this label.
Please use this number in any correspondence.
• Use the necessary mechanical liing equipment (crane, come-alongs,
etc.) for safe installation.
• e trainer should not be positioned closer than 20 feet (6M) from the
tail pulley, take-up pulleys, or head pulley.
• Follow all safety precautions when using a cutting torch.
Conveyor Site Preparation:
• Identify the point(s) of mistracking, expecting 100'- 120' (30-37 M)
of downstream inuence.
• Position the unit 20' (6 M) aer the start of the mistracking.
• Identify an opening of at least 9" (225mm).
• Remove any existing tracking devices that fall in the estimated
tracking range of the PTEZ as multiple dierent tracking devices
may reduce or prevent the PTEZ from tracking as intended.
Tools Needed:
• Tape Measure
• (2) 3/4" Wrenches (19mm)
• Medium or Large Adjustable Wrench
• Cutting Torch/Welder
• (2) Come-Alongs (3/4 Ton
Minimum)
• Any necessary equipment
for moving and liing heavy
components
• Straightedge or Level
• Marking Pen
9" (225mm)
9" (225mm)
9
Loading...